Modular Wafer Shelf Assembly for Tolerance-Controlled Containers
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Solution Overview
Problem
Conventional wafer containers require differently configured supporting shelves for variously sized wafers, leading to high production costs and assembly challenges due to large manufacturing tolerances.
Innovation Solution
A supporting shelf module comprising parallel plastic supporting plates with metal connectors at opposite ends, allowing for modular assembly and adaptation to different wafer sizes, while reducing manufacturing and assembly tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If differently configured supporting shelves are used for differently sized wafers, then wafer support accuracy is improved, but production cost increases
Solution Approach 1:
The patent applies universality by designing a single standardized supporting shelf configuration that can accommodate multiple wafer sizes (6 inches, 8 inches, 12 inches, and 15 inches). The shelf uses standard metal profiles and connectors that can be universally assembled for different container types, eliminating the need for custom-designed shelves for each wafer size while maintaining precise support accuracy.
2Weight of moving object
If injection molded plastic parts are used for supporting shelves, then weight is reduced, but manufacturing tolerance increases
Solution Approach 1:
The patent employs composite materials by combining metal components (standard metal profiles, metal connectors) with plastic elements (injection molded plastic supporting plates). The metal components provide high precision and low tolerance for critical connecting parts, while the plastic plates offer lightweight properties and cost-effective mass production. This composite approach achieves both weight reduction and tight assembly tolerances.
3Ease of manufacture
If standardized supporting shelf modules are used, then manufacturing cost is reduced, but adaptability to different wafer sizes decreases
Solution Approach 1:
The patent applies segmentation by dividing the supporting shelf into modular components: standard metal profiles, metal connectors, and plastic supporting plates. These segmented modules can be selectively assembled and configured to match different wafer sizes and container types. The modular design allows the same standardized parts to be reconfigured for 6-inch, 8-inch, 12-inch, and 15-inch wafers, maintaining both cost efficiency and adaptability.
Data Source
AI summary
A supporting shelf module includes a plurality of plastic supporting plates parallelly arranged in a height direction, and at least one pair of metal-made connectors located at two opposite ends of the supporting plates in the height direction. The connectors in one pair are correspondingly located in two horizontal planes perpendicular to the height direction. A wafer container is also disclosed, which includes a container body having at least two sets of the supporting shelf modules mounted therein, at least two top retaining brackets and at least two bottom retaining grooves provided on an inward side of a top and a bottom panel of the container body, respectively. The supporting shelf module has upper ends engaged with the top retaining brackets and lower ends engaged with and limited to the bottom retaining grooves in an engaging direction. Thus, the tolerance problem of the conventional wafer shelf can be solved.